COMPANY PROFILE · COMPANY PROFILE ZTF has been established on the basis of 20 years of experience...
Transcript of COMPANY PROFILE · COMPANY PROFILE ZTF has been established on the basis of 20 years of experience...
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COMPANY PROFILE ZTF has been established on the basis of 20 years of experience and knowledge accumulated in its
sector. Thanks to the self-confidence such an experience renders, ZTF has become a project
contracting and manufacturing firm that does not act only on customer-supplier axis but also
ensures that feasible projects and investments are realized by placing emphasis on the interests of
its customers.
The reliability of the jobs performed as well as the diligent compliance of the company to the jobs
and contracts arranged within the scope of projects has led to an increase in demand for its
services, especially combined with the company’s business ethics and quality understanding, and to
be able to meet this demand ZTF Insaat Termal Boru Sanayi ve Ticaret Limited Sirketi (Construction
Thermal Pipes Industry and Trading Limited Co.) was established in 2007. Following that, ZT
Muhendislik Musavirlik Taahhut Ticaret Firm (Engineering Consultancy Contracting Trading Firm)
was established in 2008. While ZTF emphasizes project and construction contracting jobs, ZT
Engineering concentrates on consultancy and advisory services.
ZTF, thanks to its experience especially in the field of accurate design of pre-insulated pipes used in
geo-thermal heating applications in Turkey, has become a solution partner to its clients, shouldering
and sharing their responsibility. Thanks to this understanding of business, ZTF Construction
conducts its manufacturing and assembly businesses according to TS EN 253, TS EN 448, TS EN
488, TS EN 489, and TS EN 10217-1, TS 418-2 EN 12201-2 standards.
Today, the world is on the brink of entering a new era due to the impact of global warming and thus
efficient and effective utilization of energy sources as a subject has become one of the most important
topics. Within this context ZTF contributes to the country’s economy by manufacturing pre-insulated
geo-thermal pipes that are environment friendly, besides adding value through geo-thermal projects,
aspiring to leave a clean environment to future generations. Additionally, by following the technological
innovations as well as applications across the world, ZTF endeavors to create a difference while giving
priority to the interest of the country in the field of pipeline design, manufacturing and assembly.
Talip ULUTAŞ
Mechanical Engineer General Manager
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GEOTHERMAL PIPE MANUFACTURING UNIT
FITTINGS UNIT
PIPE SANDING UNIT
CORONA UNIT
PIPE STORAGE SITE
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Why PUR insulation?
O In conventional systems reinforced concrete and steel consoles are needed.
O In conventional insulated systems, a great deal of extension element is used.
O The heat loss is too much in comparison to PUR insulation.
O Conventional insulation is affected by environmental conditions and in time the insulation
loses its quality.
For this reason its operating life is relatively short.
O As the conventional insulation material absorbs the humidity, the external corrosion on the
steel pipe is facilitated.
O In pipes with conventional insulation, the time required for assembly is too long and labour
mistakes are unavoidable.
O Heat bridges form in systems with conventional insulation.
According to the data obtained from the District Heating Handbook, a
Ø 100 diameter pipe with PUR insulation has a heat loss value of
46.29 W/m. Under the same assumptions, the heat loss of a Ø 100
mm diameter un-insulated steel pipe, when calculated in terms of W/m
would be;
Soil Temperature: 10°C
Fluid Temperature: 80 °C
∆T = 80 °C
The Handbook for Installation Engineering Figure 20.1 provides a diagram showing the heat loss
in pipes (page: 617). By using this diagram, the heat loss at 80 °C for a Ø 100 mm pipe is found
to be 300 kcal/m.h (300 kcal / mh) x(1.163 Wh/ 1 kcal) = 348.90 W/m.
When we compare these two values, it can be seen that heat savings at the rate of
348.90/46.29 = 7.54 times can be obtained. The savings achieved can increase depending on
the insulation thickness used.
The foregoing material names and their flesh thickness values provided next to them have
been calculated by taking into account the same insulation specifications. This comparison is
a response to the question “Why polyurethane?”
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STEEL PIPE PE CASING PIPE INSULATION THICKNESS PIPE LENGTH
(meter) NOMINAL DIAMETER
WALL THICKNESS
BATCH 1 BATCH 2 BATCH 3 BATCH 1 BATCH 2 BATCH 3
20 3/4" 2.6 75 90 110 29.35 39.05 46.55 6
25 1" 2.6 90 110 125 25.95 35.65 43.15 6
32 1 1/4" 2.6 110 125 140 31.30 38.80 45.80 6
40 1 1/2" 2.6 110 125 140 28.35 35.85 42.85 6
50 2" 2.9 125 140 160 29.85 36.85 46.85 6
65 2 1/2" 2.9 140 160 180 28.95 38.95 48.95 6-8
80 3" 3.2 160 180 200 32.55 - 52.35 52.35 6-8
100 4" 3.6 200 225 250 39.65 51.85 63.95 6-8
125 5" 3.6 225 250 280 39.15 51.25 65.25 6-8
150 6" 4.0 250 315 315 36.95 68.45 67.05 6-8
200 8" 4.5 315 355 400 43.05 84.15 82.45 6-8-12
250 10" 5.0 400 450 500 57.20 81.50 105.70 6-8-12
300 12" 5.6 450 500 560 56.05 80.25 109.25 6-8-12
350 14" 5.6 500 560 630 64.40 93.40 127.40 6-8-12
400 16" 6.3 560 630 710 68.00 102.00 140.70 6-8-12
450 18" 6.3 630 710 800 76.70 115.40 159.00 6-8-12
500 20" 6.3 710 800 900 89.90 133.50 183.10 6-8-12
600 24" 7.1 800 900 1000 82.50 132.10 181.70 6-8-12
700 28" 8.0 900 1000 1100 81.60 131.20 180.70 6-8-12
800 32" 8.8 1000 1100 1200 80.20 129.70 178.00 6-8-12
900 36" 10.0 1100 1200 1400 79.20 128.40 228.00 6-8-12
1000 40" 11.0 1200 1400 77.40 177.00 6-8-12
1200 48" 12.5 1400 75.50 6-8-12
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PRODUCTION STANDARDS: TS EN 253, TS EN 448, TS EN 489, TS EN 488
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The pipes with pre-insulation, when manufactured in compliance with TS EN 253 standard, have an insulation life of 30 years at 120°C of operating temperature, 50 years at 115°C operating temperature and more than 50 years when used at temperatures less than 115°C.
� Thermal Conductivity at 50°C is 0.03 W/mK � Thermal Conductivity remains the same all through the life-span of the insulation (min 30
years). � Heat loss is negligibly low and the operating cost throughout the life-span of the insulation
is fixed. � Its assembly is easy and ensures savings both in terms of time and labour and
workmanship errors are minimized. � There is no need for a gallery as the product is directly immersed in the soil. � CORONA, which is applied to PE pipes, ensures that the pipe system moves as an
integrated whole. � Expansion elements are neither used nor minimized, depending on the laying technique
used. � Thanks to the integrated movement capability of the system, the pipes are pre-tensioned
and expansion elements are not used. � In Console top applications inside the gallery, the supports are applied on the external
sheath, preventing the formation of heat bridges. � The sheath protects the pipe service pipe and insulation material from outside effects at
the rate of 100%. � There is no maintenance cost following the application. � All kinds of fittings can be manufactured. Certificates on the basis of Fittings Standard TS
EN 448 and Joint Insulation Standard TS EN 489 are available. � The diameter of the service pipe and sheath pipe diameter can be selected from different
materials depending on the type of the project. � The pipe lengths can be manufactured as 6-8-12 m. � Manufacturing, with monitoring wire, used to observe leaks is possible. FIELDS OF UTILIZATION OF PRE-INSULATED PIPES � In geothermal regional heating and cooling systems � Central heating and cooling systems � In fire lines � Cold water lines with the possibility of freezing � Cogeneration system � Textile, chemical, etc. factory facilities � Geothermal greenhouse heating � Gas and oil (petroleum) pipelines � Vessel installations � Industrial facilities where any kind of fluid whether hot or cold is transmitted
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The double insulation pipes that are used at high temperatures are designed for
temperatures higher than the standard type pre-insulated pipes (140 ° C and above).
The most important issue where the design temperature is concerned is achieving
economical usage. As a design criterion, the thickness of the first layer is selected such that
the external surface temperature of this layer is 120 ° C (calcium silicate or rock wool). The
thickness of the second layer (polyurethane) is determined on the basis of the project
information.
O This type of pipe is used at temperatures above the standard for which pre-insulated
pipes have resistance. (140°C and above)
O With the second layer, the low heat conductivity coefficient of PUR is taken advantage
of and a pipe design with even less heat loss is achieved (optimum heat loss)
O An insulation thickness that is less than what it would have been with conventional
insulation materials is achieved. (Optimum Insulation thickness)
O The second layer of PUR and PE Sheath protect the first layer of insulation material
from all the external factors.
O As the insulation will be protected against external factors, the life-span of the
insulation will be equal to the life of a PUR insulated pipe.
O The manufacturing is factory based and as such workmanship errors are minimized.
O Assembly work ensures time is saved.
O It can be used in underground and surface applications. It is resistant to UV Light.
O Especially when used on decks of ships, the service pipes and insulation are perfectly
protected against environmental factors, such as sea water, rain, wind, etc., thanks to the
external sheath PE
O In circumstances where the assembly environment of the pipe is corrosive, the service
pipe and insulation are not subjected to corrosion thanks to the external sheath PE.
FIELDS OF UTILIZATION OF DOUBLE INSULATED PIPES O Very hot water lines
O Steam lines
O Superheated oil lines
O Vessel installations
O Cogeneration systems
O Textile factories
O Sugar factories
O Energy power plants
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Sanding is a surface cleaning process
used for steel pipes. Subjecting the
steel pipe to sanding before insulating
with polyurethane foam ensures
adhesion of the insulation material to
the steel pipe is better and that the
entire piping system moves as a
whole. In this manner the length of
service life of both the product and
insulation will improve. Otherwise, the
piping system, which consists of steel
pipe, polyurethane and polyethylene,
will start to separate from each other
as a result of expansion. This severely
shortens the life-span of pre-insulated
pipes. By keeping the foregoing in
mind, and to be able to provide better
quality products with longer life-spans
to our customers, we established a
sanding unit at our pre-insulated pipe
manufacturing facilities.
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The Corona process is a procedure applied
to the inner surfaces of polyethylene pipes
used as sheaths. During this process, high
tension is applied to the inner walls of the
polyethylene pipes to sever the carbon
ligaments. As a result of this process, a
fringed structure that would ensure better
adhesion of the polyurethane on
polyethylene is achieved, and consequently
the entire piping system moves as a whole.
As such the life-span of both the product and
insulation will improve. Otherwise, the piping
system, which consists of steel pipe,
polyurethane and polyethylene, will start to
separate from each other as a result of
expansion. This severely shortens the life-
span of pre-insulated pipes. It is worth noting
that the effect of the Corona Process
diminishes if a processed product spends too
much time in transportation or storage.
Therefore, pipes that go through the corona
process must be promptly subjected to the
polyurethane injection procedure. By keeping
the foregoing in mind, and to be able to provide better quality products with longer life-spans to our
customers, we established a corona processing unit at our pre-insulated pipe manufacturing facilities.
Polyethylene pipes that are subjected to the corona process are used in all the pre-insulated pipes
manufactured.
Some people may consider these two stages of manufacturing as a burden, thinking of these
processes as an unnecessary use of time and labour. However, these production stages are
intermediary levels that are vital for the quality of the product manufactured. They lengthen the life-
span of the product to a great extent. Therefore, these manufacturing steps are adopted as a means to
provide better quality products for our customers.
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PROJECT DESIGN INFORMATION HEAT LOSS CALCULATION
Q = Meter compression heat loss for a pair of pipes W/m2
U = Overall Heat transfer coefficient for a single pipe W/m2K
tg = fluid outlet temperature °C
td = fluid inlet temperature °C
Overall Heat transfer coefficient U is calculated by using the formula below.
Rpur= Polyurethane thermal resistance mK/W
Rç= Thermal resistance of steel pipe mK/ W
R pe= Thermal resistance of sheath pipe mK/W
Rt= Thermal resistance of soil mK/W
RH= Thermal resistance of the temperature change between
the outgoing and incoming pipes mK/W
CALCULATION OF THERMAL RESISTANCE VALUES
Di= Sheath pipe inner diameter m
D= Sheath pipe outer diameter m
di= Steel pipe inner diameter m
d= Steel pipe outer diameter m
z= Distance of the pipe’s center to the surface of the soil m
λpur= Polyurethane thermal conductivity 0.029W/ mK
λpe= Sheath pipe thermal conductivity 0.43W/mK
λc= Steel pipe thermal conductivity 76W/mK
λt=Thermal conductivity of soil 1.5 W / mK
C=Distance between the centers of the two pipes m
Soil thickness above the pipe = 800mm
Distance between two sheaths = 150 m
THERMAL EXPANSION
The first expansion of the steel pipe following the pipe padding and filling is calculated by means of the
formula provided below. (Assuming ideal padding and manufacturing according to the pipe standard)
∆L = Expansion (m)
a = Expansion coefficient of the steel pipe 1,2x10
ti = Operating temperature °C
td = Flooring temperature °C
L = Pipe length (m)
A = Cross sectional of the steel pipe mm2
E = Modulus of elasticity for the steel, 1x105 N/mm²
F =Friction force N/m
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MAXIMUM LAYING LENGTH OF THE PIPE σ the axial stress of the steel pipe increases with the distance from the point of elongation.
The maximum laying length of the pipe Lmax, is determined by means of the safety stress of
the steel pipe. Lmax is determined by means of the formula provided below.
Lmax = Maximum laying length of the pipe m
σem = Safety stress of the steel pipe N/mm2
A = Cross sectional area of the steel pipe mm2
F = Unit length friction force N/mm
D = Sheath pipe diameter m
z = Lay down depth from the central line of the pipe m
γ = Specific weight (soil) N / m³
µ = Friction coefficient between the soil and sheath
pipe (For Normal movement n= 0.4)
METHODS FOR LAYING DOWN PRE-INSULATED PIPES
1. SYSTEM WITH COMPENSATOR In a system with a compensator, the filling process is carried out according to the appropriate
technique following the completion of pipe assembly. The expansion is absorbed by means
of axial compensators placed along the route. The distance between the compensators
depends on the friction force between the sheath pipe and soil and the safety stress of the
steel pipe.
2. PRE-TENSIONED SYSTEM Following the assembly of the pipes and before closing the channel, up to half of the
operating temperature is pre-heated. The pre-heating can be accomplished by means of hot
water, electricity or steam. After the elongation of the pipe is achieved, the channel is closed
by using an appropriate technique. After the filling process, the system is commissioned.
If later on the system drops below the pre-heating temperature, then tensile stress will form
in the steel pipes. In selecting the pre-heating temperature, care must be taken to design it in
a manner that will ensure the elongation stress at operating temperature and the tensile
stress in cooling are the same and that they never exceed the safety stress.
When the process to lay down the line is completed, it is necessary to leave the channel
open. The axial stress in the pre-tensioned area is calculated on the basis of the formula
provided below.
σe = Axial stress N/mm2
E = Elasticity Module N/mm2
α = Elongation coefficient K-1
∆t = Temperature difference K
If (ti- td) is 120 °C, then the pre-tensioning temperature is calculated as follows
ti =Operating temperature °C
td =Lay down temperature °C
tön ısı = Pre-heating temperature
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3. LAYING WITH ULZ EXPANSION ELEMENT
A) U Expansion Element The elongation with U expansion element is absorbed as shown in the figure provided below. A space is left in order to ensure movement in the elongation region.
B) L Expansion Element: The elongation with L expansion element is
absorbed as shown in the figure provided below. A space, which would ensure movement in the elongation region, is created or supported by means of PE padding.
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C) Z Expansion Element: The elongation with Z expansion element is absorbed as shown in the figure provided below. A space that would ensure movement in the elongation region is left.
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EXCAVATION Unstable ground should be made suitable for the installation of the pipe. To ensure this, a 10-cm grading should be performed in a manner allowing sand to be laid beneath the pipeline. In wet surfaces, water must be drained.
STEEL SERVICE PIPE INSTALLATION The welding of the service pipe to be installed should be made in accordance with a welding technique and EN 287-1 standard. Radiographic examination should be in accordance with EN 444 and EN 1435. INSULATION OF JOINT
a) Prior to steel service pipe installation, the external sheath casing pipe should be covered with the connection set. After necessary tests are performed following the completion of the welding of the steel service pipe, the surfaces on which the connecting set will be laid should be cleaned with a solvent or alcohol.
b) The connection set should be placed on the steel pipe sheathing by centering it in a manner allowing them to superimpose each other with a minimum 10-cm length, and the surface of parts of the connection set and pre-insulated package pipe to be wrapped with heat shrink-wrapped band should primarily be cleaned with solvent or alcohol, and then sanded with a wire brush until the gloss fades.
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c) After the sanded surface is
heated with a blow torch, the
heat shrinking bands must be
applied to the heated surfaces
by again using the blow torch,
to ensure impermeability. In
circumstances where the
ambient temperature falls
below +10°C or exceeds
+40°C, the heat shrinking
bands must be wrapped.
After the assembly process
is completed, leakage tests
must be conducted, and by
using polyurethane injection,
the assembly of the joining set
must be completed.
The insulation of the seam
can also be accomplished by
means of a heat shrinking
electro-fusion joining set. There
must be pipe setting and
welding on the pipe.
The seam can also be
insulated by means of a self-
shrinking joining set.
FILLING After the assembly of the
pipe is completed, sand filling is
made so that the top of the pipe
is covered with at least 10 cm
of sand. The sand filling is
covered with soil filling and this
filling is compressed either
manually or by means of
machinery to complete the
process.
In the underground
application of a double
insulation pipe, great care must
be taken in the manufacturing,
project preparation and
application stages.
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It will be possible to determine any leakages occurring in the system with the help of two wires placed within the pipe at the manufacturing phase, one being a PTFE coated copper (Cu), and the other being a Chromium-nickel (Cr-Ni) wire. Low operating cost, advanced system control and automation, the ability to instantly intervene with the system, and its control from a single center are all performed through the leakage observation system. Thus the effects of possible water leakages on the system and the operation are prevented, system efficiency is increased, and operating costs are reduced to minimum levels. Interfaces placed between 500-1250 m according to the project geometry, transfer system parameters to the central unit by continuously measuring them. The central unit is the component that collects system parameters, keeps the records, and provides connection with other automation systems. The communication protocol of the system is realized by using either cable communication or RF communication modules depending on the size of the project. A connection can be made to a signalization system, if need be, during the Leakage Observation System optimization. Software used by the system may be custom revised according to the project. A) TOOLS REQUIRED PRIOR TO INSTALLATION These are: a multimeter (with buzzer feature), grip cable (to determine short-circuit), cable pliers (to install terminals), terminals (to make the connection of wires, insulated type), and side cutter for system installation. B) CHECKS PRIOR TO INSTALLATION 1) It is necessary to perform a conductivity check between Cr-Ni and Cu wire and the pipe. Prior to performing this check, the pipes are short-circuited from one end with the grip cable while checking is made on the other end.
Following the connection (see Figure 1) a check is made by using the BIZZ (Buzzer) level of the multimeter. If no sound is emitted by the multimeter, then the state of the wires are normal. If there is sound coming out of the multimeter, this means that there is leakage in the body. 2) Cr-Ni and Cu wire should be checked for disconnection. Prior to performing this check, the pipes are short-circuited from one end with grip cable, while checking is made on the other end.
Following the connection (see figure 2) a check is made by using the BIZZ (Buzzer) level of the multimeter. If no sound is emitted by the multimeter, then the state of the wires are normal. If sound comes from of the multimeter, this means there is leakage in the body.
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C) PERFORMING THE INSTALLATION Prior to commencing the installation, care should be taken to ensure that the installation process of the service pipe is completed and that the connection-set is mounted on the enclosure pipe. 1) The wires are made ready for installation by being cut with a side cutter (see Figure 3).
2) Wire joining connectors are locked as shown in the figure (see Figure 4)
3) Connectors are clenched with the use of cable pliers, and excess parts are cut by using the side cutter (see Figure 5). Wire tension should be finely adjusted during the performance of this process.
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PARK HOTEL Ø200 - 250 mm
Pre-insulated Geothermal Water Distribution Pipeline Manufacturing and
Undertaking Sandıklı /AFYON
KUZULUK THERMAL RESIDENCES Regional Heating Consultancy Services
and Geothermal Central Heating Rehabilitation Project Akyazı/ADAPAZARI
KOREL HOTEL Deva Termal Tur. Tic. A.Ş.
Ø150mm 2500 mt Pre-insulated Pipe Manufacturing and Undertaking
AFYON
Bostan Tarım Ürünlerileri Seracılık ve
Gıda Sanayi Tic. Ltd. Şti. 120,000 m2 Greenhouse Installation
Sandıklı/AFYON
IZMIR Jeotermal Enerji San. Tic. A.S.
3200 KE Geothermal Regional Heating System Construction
Balçova/lZMlR
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Chimney Installation Cooling Tower Installation
Steel Construction and Exhaust Chimney
Installation 3-4-5-6 Units of Natural Gas Combined Cycle
Power Plant
Steam and Water Pipeline Construction
Station Mechanic Installations Assembly
Usak Combined Leather Organized Industrial Zone Degassing Installation
SONMEZ ENERJI A.S. / USAK
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Revision Installation of Heating Center
Number Intra-city Water Distribution Pipelines
Heating Center Number 4
1200 KE Geothermal Regional Heating Project Planning Procurement of
Pre-insulated Pipes Ø25 -500 mm 62.00 m
Main Water Pipeline Ø400 Pre-insulated Pipe Installation 3100 m
Main Water Pipeline
Ø500 Pre-Insulated Pipe Assembly 5200m SANJET ENERJİ A.S /USAK
Intra-city Water Distribution Pipelines
SANJET JEOTERMAL A.Ş – SANDIKLI/AFYON
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City Sewer Lines Installation Intra-city Distribution Lines Installation
DENIZLI Special Provincial Administration
Thermal Water Distribution and Waste-Water Project undertaking work
Geothermal Force Main Center
Intra-city Distribution Lines Karahayıt / DENIZLI
DENIZLI SPECIAL PROVINCIAL ADMINISTRATION KARAHAYIT / DENIZLI
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10000 KE Geothermal Regional Heating Main Water Pipeline ∅∅∅∅ 600 mm 28000 m
Pre-isolated Pipe Production
DERVIŞ PAŞA Heating Center
GECEK Heating Center
10000 KE Geothermal Regional Heating Project and Consultancy Service and Pre-
isolated Pipe Production
In-city Distribution Lines
Main Water Pipeline
∅∅∅∅600/800 Pre-isolated Pipe Main Water Pipeline
Compensator Installation
AFJET A.Ş. / AFYON
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� SANJET Geothermal Inc. Sandıklı Center System Automation System Installation
Sandıklı / AFYON
� Mersin 5 Regional Directorate of Highways
Central Heating System Works
MERSİN
� TAI Aviation Joint Stock Company
Hot Water Pipe Change Job
Kazan / ANKARA
� Ma-Ya Building Construction Commitment Industry Domestic and Foreign Trade Limited
Company
Ünye / ORDU
� Goksan of Clinical Physical Therapy Health Tourism Limited Company
Sandıklı / AFYON
� Thracian Union of Oil Seeds Agricultural Sales agriculture cooperatives
Çorlu / TEKİRDAĞ
� City of Plant Sandıklı BSOM Sandıklı/AFYON
� Tech Mechanical Engineering Services Electrical Mechanical Mining Industry and trade
Limited Company
Çaycuma / ZONGULDAK
� Construction Turhallar thermal Pipe Industry and Trade Limited Company
Nazilli / AYDIN
� Positive Textile Marketing Industry Trade and Limited Liability Company
UŞAK
� Altunc Automotive Construction Tourism Hotel Industry Trade and Limited Liability
Company
Bostancı / EDREMİT
� Technical Heat Service Engineering Limited Company
Esenyurt / İSTANBUL
� Cakir Special Education Instructional Services Construction Agriculture and Trade Joint
Stock Company
Nilüfer / BURSA
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